Development and research of new technologies for precision plasma cutting of metals

2021 ◽  
Vol 77 (7) ◽  
pp. 829-834
Author(s):  
S. V. Anakhov ◽  
Yu. A. Pykin ◽  
A. V. Matushkin ◽  
B. N. Guzanov
Keyword(s):  
Plasma Torch ◽  
Metal Cutting ◽  
New Technologies ◽  
Arc Discharge ◽  
Experimental Studies ◽  
Carbon Steels ◽  
Plasma Cutting ◽  
Medium Thickness ◽  
Plasma Torches ◽  
Gas Dynamic

Plasma torches of Russian origin concede to import metal-cutting plasma facilities by several parameters, in particular energy efficiency, quality of cut, degree of automation. To increase efficiency and safety of domestic electro-plasma technologies itь is necessary to perfect methods of analysis of known design solutions to provide new developments. The results of the plasma torch­es design widely used in metallurgical and machine-building technologies for air-plasma cutting of metals presented. It was noted that productivity, cutting quality and reliability of plasma equipment should be chosen as the main criteria of efficiency for plasma cutting technology. It was shown that special attention should be paid to improving the gas-vortex stabilizing method for the plasma forming gas, which ensures the efficiency of both the plasma torch and the plasma cutting process as a whole. Results of studies of a complex system for arranging the flow of plasma-forming gas through the channels of the gas-air path in the plasma torch and the subsequent creation of new systems for stabilizing the arc discharge of metal cutting DC plasma torches with high technological capabilities presented. The study was carried out by the methods of numerical simulation of gas-dynamic and thermo-physical pro­cesses for various designs of plasma torches. Optimized designs of plasma torches with various variants of gas-vortex stabilization systems were elaborated. A series of elaborated torches, which includes a single-stream plasma torches ПМВР-5 for precision cutting of medium thickness metals, as well as two-stream plasma torches ПМВР-9 for cutting metals of small and medium thicknesses presented. The last plasma torches use the technology of narrow-jet or compressed plasma and have no domestic analogues. A meth­odology of metal-cutting plasma torches designing by gas-dynamic, thermo-physical and acoustic criteria was elaborated. The results of experimental studies  showed that the use of new ПМВР-5 plasma torches allows to obtain precision cuts corresponding to the 1st and 2nd quality classes according to GOST 14792-80 on steels of the 09Г2С type of medium thickness. It was also shown that the use of new plasma torches makes it possible to perform precision finishing plasma cutting on low-carbon steels of medium thickness (without additional mechanical processing of the cutting edge) in the production technologies of welded joints.

scholarly journals Design of a new gas-dynamic stabilization system for a metal-cutting plasma torch

2021 ◽  
Vol 2094 (4) ◽  
pp. 042075
Author(s):  
I Yu Matushkina ◽  
S V Anakhov ◽  
Yu A Pyckin
Keyword(s):  
Velocity Distribution ◽  
Cross Section ◽  
Plasma Torch ◽  
Metal Cutting ◽  
Evaluation Method ◽  
Dynamic Stabilization ◽  
Stabilization System ◽  
Plasma Torches ◽  
Gas Dynamic ◽  
The Cross

Abstract The analysis of the influence of various design solutions of the gas-dynamic stabilization system in plasma torches for cutting metals on the efficiency of equalizing the velocities of gas flows along the cross-section of the gas path is carried out. It is noted that the efficiency evaluation method developed by the authors should be based on the calculation of the uniformity of the gas flow velocity distribution over the cross-section of the gas-air path of the plasma torch. A vortex stabilization system using two swirlers is proposed. The effect of improving the reliability and quality of plasma cutting is shown. The results of the efficiency studies for the proposed system of gas-vortex stabilization in metal-cutting plasma torches are presented. The calculating results of equalization coefficients for the velocity distribution in different parts of the gas-dynamic stabilization system in the plasma torch are presented. Based on the results of the calculations, a constructive optimization of the gas-air path in the plasma torch was performed. The experimentally obtained advantages of the new upgraded plasma torch in terms of the gas-vortex stabilization efficiency are demonstrated. The effects of improved cutting quality and reduced nozzle wear in the new plasma torch are shown. This is due to the higher degree of the plasma arc stabilization in the new plasma torch, which leads to a decrease in its oscillations, and, consequently, to an increase in the efficiency of the cutting process.

scholarly journals Influence of plasma torch design on cutting quality during precision air-plasma cutting of metal

2020 ◽  
Vol 63 (2) ◽  
pp. 155-162
Author(s):  
S. V. Anakhov ◽  
B. N. Guzanov ◽  
A. V. Matushkin ◽  
N. B. Pugacheva ◽  
Ya. A. Pykin
Keyword(s):  
Plasma Torch ◽  
Dynamic Stabilization ◽  
Quality Analysis ◽  
Metallographic Analysis ◽  
Plasma Cutting ◽  
Plasma Arc ◽  
09G2s Steel ◽  
Plasma Torches ◽  
Gas Dynamic

Optical interferometry and metallographic analysis were used to study structure of cutting seams obtained after 09G2S steel cutting by PMVR-5 plasma torch. These plasma torches have a number of design features in the system of gas-dynamic stabilization of plasma arc. It is shown that application of new plasma torch allows obtaining higher quality of cutting 09G2S steel of medium thickness with high productivity and lower energy costs. Metallographic analysis has shown that qualitative composition of the cut surface structure is almost the same, so priority criteria for comparative quality analysis are parameters of surface microgeometry. Evaluation of this parameter shows high quality of cutting almost along the entire length of a cut, since the influence of technological features of plasma arc cut into the metal affects at a distance of less than 0.3 mm from the edge of the sheet. The use of additional methods of gas-dynamic stabilization in PMVR -5.2 plasma torch (feed symmetry with a double swirl system of plasma-forming gas) allows to achieve additional advantages in terms of surface quality compared to PMVR -5.1. A number of features that affects quality of cut when cutting metals of different thicknesses for welding, is noted depending on the angle of inclination of plasma torch during cutting. Estimates of the surface layer hardness indicate minimal deviations from the requirements of GAZPROM Standard 2-2.4-083 (instructions on welding technologies in the construction and repair of field and main gas pipelines), which allows further use of cutting seams obtained by studied plasma torches for welding without removing zones of thermal influence. Thus, application of new plasma torches makes possible precision finishing plasma cutting of metals, including production of welded joints.

Hybrid Induction Plasma Cutting Process - A New Technology for High Speed Metal Cutting

2014 ◽  
Author(s):  
Jerald E. Jones ◽  
Valerie L. Rhoades ◽  
Mark D. Mann ◽  
Todd Holverson
Keyword(s):  
Induction Heating ◽  
Plasma Torch ◽  
High Speed ◽  
Metal Cutting ◽  
New Technology ◽  
Cutting Process ◽  
Plasma Cutting ◽  
Air Plasma ◽  
Aircraft Carrier ◽  
Initial Development

A new cutting process, a hybrid system, uses induction heating to heat the metal ahead of the plasma cutting torch. The process has demonstrated the ability to plasma cut steel parts at speeds of up to 4X the speed of the plasma torch without the induction heating. Although the total heat input per unit time is greater, because of the increase in speed, the heat which is conducted into the cut pieces is less. This causes less potential metallurgical damage, less potential distortion, and reduced coating damage and reduced emissions during cutting, in comparison to the plasma cutting process without the induction heating. The initial development was primarily for use in cutting nuclear submarine and aircraft carrier hulls, for scrapping after decommissioning. The process has been demonstrated cutting steel plates and can be used in ship production as well. The primary motivation of the SBIR project was to reduce the heating of the cut pieces, in order to reduce the particulate matter (PM) emissions which occur when coated ship hull material is cut. An induction coil is positioned in front of the plasma cutting torch, to bring the material to an elevated temperature of at least 1600° F, before the plasma is applied to the metal surface. Induction heating testing has shown that the 35 kW induction system can maintain the 1600° F surface temperature at travel speeds of above 220 inches per minute on steel as thick as 3 inches. Once the steel is at that temperature an air plasma torch can cut the metal much faster than cutting cold steel.

scholarly journals Gas-dynamic aspects of new metal-cutting plasmatron design

2021 ◽  
Vol 2021 (5) ◽  
pp. 7-13
Author(s):  
Sergey Anakhov ◽  
Anatoliy Matushkin ◽  
Yuriy Pykin
Keyword(s):  
Flow Rate ◽  
Gas Flow ◽  
Metal Cutting ◽  
Dynamic Stabilization ◽  
Plasma Cutting ◽  
Gas Flow Rate ◽  
Gas Dynamic ◽  
Design Solutions ◽  
The Impact

The analysis of the impact of different design solutions for the system of plasmatron gas-dynamic stabilization for metal-cutting upon effectiveness of gas flow rate balance according to the section of a gas path is carried out. A system of turbulent stabilization, using two swirlers is offered. The effect of plasma cutting reliability and quality is shown.

About Raising of the Gas Vortex Stabilization Efficiency in Plasma Torch for Metal Cutting

2018 ◽  
Vol 284 ◽  
pp. 218-223
Author(s):  
A.V. Matushkin ◽  
Yu.A. Pyckin ◽  
S.V. Anakhov ◽  
I.Y. Matushkina
Keyword(s):  
Plasma Torch ◽  
Metal Cutting ◽  
Gas Distribution ◽  
Gas Dynamic ◽  
Distribution Uniformity ◽  
Dynamic Filters ◽  
The One

Influence of gas distribution uniformity in the channels of air-gas paths on efficiency and quality of metals cutting is noted for plasmatrons of various updating. It is shown, that application of gas-dynamic filters promotes efficiency and quality of plasmatrons with the one-line scheme of air-gas pathswork. The technique for estimation of gas distribution uniformity in the channels of metal-cutting plasmatron is presented.

Evaluation of the Effectiveness of Plasma Torches Design for Metal Cutting by Qualimetric Method

2019 ◽  
Vol 946 ◽  
pp. 877-882
Author(s):  
I.Y. Matushkina ◽  
S.V. Anakhov ◽  
Yu.A. Pyckin
Keyword(s):  
Metal Cutting ◽  
Quality And Safety ◽  
Plasma Cutting ◽  
Plasma Arc ◽  
Work Efficiency ◽  
Integral Evaluation ◽  
Plasma Arc Cutting ◽  
Plasma Torches ◽  
Safety Parameters ◽  
Experimental Substantiation

For experimental substantiation of plasmatrons work efficiency the technological regulations of quality and safety parameters test for plasma-arc cutting of metals technology are taken. For the integral evaluation of the obtained results it is proposed to use the methods of qualimetric analysis adapted to the technology of plasma cutting. The obtained integral parameters indicate the effectiveness of the new plasmatrons, designed by the authors in comparison with previously produced analogues, as well as with modern domestic and foreign samples.

scholarly journals Improvement Dependability of Offshore Horizontal-Axis Wind Turbines by Applying New Mathematical Methods for Calculation the Excess Speed in Case of Wind Gusts

Energies ◽  
2021 ◽  
Vol 14 (11) ◽  
pp. 3085
Author(s):  
Konstantin Osintsev ◽  
Seregei Aliukov ◽  
Alexander Shishkov
Keyword(s):  
Computer Simulation ◽  
Wind Turbines ◽  
Experimental Studies ◽  
Offshore Wind ◽  
Approximation Schemes ◽  
Calculation Error ◽  
Strong Wind ◽  
Mathematical Methods ◽  
Wind Gusts ◽  
Gas Dynamic

The problem of increasing the reliability of wind turbines exists in the development of new offshore oil and natural gas fields. Reducing emergency situations is necessary due to the autonomous operation of drilling rigs and bulk seaports in the subarctic and Arctic climate. The relevance of the topic is linked with the development of a methodology for theoretical and practical studies of gas dynamics when gas flows in a pipe, based on a mathematical model using new mathematical methods for calculation of excess speeds in case of wind gusts. Problems in the operation of offshore wind turbines arise with storm gusts of wind, which is comparable to the wave movement of the gas flow. Thus, the scientific problem of increasing the reliability of wind turbines in conditions of strong wind gusts is solved. The authors indicate a gross error in the calculations when approximating through the use of the Fourier series. The obtained results will allow us to solve one of the essential problems of modeling at this stage of its development, namely: to reduce the calculation time and the adequacy of the model built for similar installations and devices. Experimental studies of gas-dynamic flows are carried out on the example of a physical model of a wind turbine. In addition, a computer simulation of the gas-dynamic flow process was carried out. The use of new approximation schemes in processing the results of experiments and computer simulation can reduce the calculation error by 1.2 percent.

scholarly journals Influence of Plasma Torch Design on Cutting Quality during Precision Air-Plasma Cutting of Metal

2020 ◽  
Vol 50 (3) ◽  
pp. 159-165 ◽  
Author(s):  
S. V. Anakhov ◽  
B. N. Guzanov ◽  
A. V. Matushkin ◽  
N. B. Pugacheva ◽  
Yu. A. Pykin
Keyword(s):  
Plasma Torch ◽  
Plasma Cutting ◽  
Air Plasma ◽  
Torch Design

Thermal and mechanical improvement of the air supply system of a turbocharged piston engine

2021 ◽  
Vol 14 (2) ◽  
pp. 108-114
Author(s):  
Y. M. Brodov ◽  
L. V. Plotnikov ◽  
K. O. Desyatov
Keyword(s):  
Heat Transfer ◽  
Experimental Studies ◽  
Local Heat Transfer ◽  
Supply System ◽  
Scale Model ◽  
Piston Engine ◽  
Intake System ◽  
Gas Dynamic ◽  
Air Supply ◽  
Air Flows

A method of thermomechanical improvement of pulsating air flows in the intake system of a turbocharged piston engine is described. The main objective of this study is to develop a method for suppressing the rate of heat transfer to improve the reliability of a piston turbocharged engine. A brief review of the literature on improving the reliability of piston engines is given. Scientific and technical results were obtained on the basis of experimental studies on a full-scale model of a piston engine. The hot-wire anemometer method was used to obtain gas-dynamic and heatexchange characteristics of gas flows. Laboratory stands and instrumentation facilities are described in the article. The data on gas dynamics and heat exchange of stationary and pulsating air flows in gas-dynamic systems of various configurations as applied to the air supply system of a turbocharged piston engine are presented. A method of thermomechanical improvement of flows in the intake system of an engine based on a honeycomb is proposed in order to stabilize the pulsating flow and suppress the intensity of heat transfer. Data were obtained on the air flow rate and the local heat transfer coefficient both in the exhaust duct of the turbocharger compressor (i.e., without a piston engine) and in the intake system of a supercharged engine. A comparative analysis of the data has been carried out. It was found that the installation of a leveling grid in the exhaust channel of a turbocharger leads to an intensification of heat transfer by an average of 9%. It was found that the presence of a leveling grid in the intake system of a piston engine causes the suppression of heat transfer within 15% in comparison with the baseline values. It is shown that the use of a modernized intake system in a diesel engine increases its probability of failure-free operation by 0.8%. The data obtained can be extended to other types and designs of air supply systems for heat engines.

scholarly journals Microwave Plasma Torch Generated in Argon for Small Berries Surface Treatment

2018 ◽  
Vol 8 (10) ◽  
pp. 1870 ◽  
Author(s):  
Todor Bogdanov ◽  
Ivan Tsonev ◽  
Plamena Marinova ◽  
Evgenia Benova ◽  
Krasimir Rusanov ◽  
...  
Keyword(s):  
Surface Wave ◽  
Plasma Torch ◽  
New Technologies ◽  
Microwave Plasma ◽  
Uv Light ◽  
Strong Electric Field ◽  
Surface Shape ◽  
Activity Measurements ◽  
Surface Decontamination ◽  
Fruit Surface

Demand for food quality and extended freshness without the use of harmful chemicals has become a major topic over the last decade. New technologies are using UV light, strong electric field, ozone and other reactive agents to decontaminate food surfaces. The low-power non-equilibrium (cold) atmospheric pressure operating plasmas effectively combines all the qualities mentioned above and thus, due to their synergetic influence, promising results in fruit surface decontamination can be obtained. The present paper focuses on the applicability of the recently developed microwave surface wave sustained plasma torch for the treatment of selected small fruit. Optical emission spectroscopy is used for the determination of plasma active particles (radicals, UV light) and plasma parameters during the fruit treatment. The infrared camera images confirm low and fully applicable heating of the treated surface that ensures no fruit quality changes. The detailed study shows that the efficiency of the microbial decontamination of selected fruits naturally contaminated by microorganisms is strongly dependent on the fruit surface shape. The decontamination of the rough strawberry surface seems inefficient using the current configuration, but for smooth berries promising results were obtained. Finally, antioxidant activity measurements demonstrate no changes due to plasma treatment. The results confirm that the MW surface wave sustained discharge is applicable to fruit surface decontamination.

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